Upholstery forming apparatus



Feb. 6, 1940. c. w. AVERY n AL UPHOLSTERY FORMING APPARATUS 7 Shets-Sheet 1 Filed March 9, 1936 AT RNEYS Y R E SW R. 0 w T m Vm NR IIA L BY ALFRED H. HABER5TUMP M m PM Feb. 6,1940.

c. w. AVERY El AL UPHOLSTERY FORMING APPARATUS 7 Sheets-Sheet 2 INVENTORS v CLARENCE W AVERY BY ALFRED H. HABERSTUMP 4 0 w/mwaj @zc flwarfiwd Filed March 9, 1936 AT T01 NEYS.

Febrfi, 1940. c. w. AVERY :1- AL UPHQLSTERY FORMING APPARATUS Filed March 9, 1956 7 Sheets-Sheet 4 INVENTORS CLARENCE WAVERY BY ALFRED H.HABER$TUMP A ORNEYS Feb. 6, 1940. c. w. AVERY El AL UPHOLSTERY FORMING APPARATUS Filed March 9, 1956 '7 Sheets-Sheet 5 Wm mm vrlr l 1 1 ifiamiiifiisf h l .v R 3 a Q... &.... i H h n P J M N aw M H H wm hm L 9\\\ 0 v .m hm uwi P W Y R m .r f A E s Y S B E R w A H N O E R TCH N N D WEE T NRR l A F LL imp Y .B

Feb. 6, 1940. c. w. AVERY ET AL UPHOLSTERY FORMING APPARATUS '7 Sheets-Sheet 6 Filed March 9, 1936 W m V! mm 5 SVE Y R E ow N T HpR NEH. 0 EM T VEM A NRR. I Q Y 1 B Feb. 6, 1940. c. w. AVERY ET AL UPHULSTERY FORMING APPARATUS Filed March 9, 1936 7 Sheets-Sheet 1 Y R E V A mm a N EE R MA L Y B FRED H. HABERSTUMP mm E N J R O I A Patented Feb. 6, 1940 UNITED STATES PATENT OFFIQE v UPHOLSTERY FORMING APPARATUS Clarence W. Avery and Alfred I-I. Haberstump, Detroit, Mich., assignorslto' The Murray Core poration of America, a corporation of Dela-.

ware

Application March 9,

v 3 Claims.

This invention relates to upholstery forming machinery. More particularly, it relates to a specific type of upholstery forming machine adapted for the continuous preparation of padded upholstery panels for use in automobile seat backs and cushions.

The present invention contemplatesthe provision of a plurality of correlated units which are arranged together and synchronouslyoperated in order to form unit upholstery panels. These upholstery panels comprise a pair of fabric members with a bat or stuffing layer of non-woven fibrous padding material secured in-position therebetween to constitute padding for the panel as a whole. Panels of the general type with which the machinery of the present application is primarily concerned, usually constitute a backing sheet of woven'fabric and ,a reveal section of finish fabric with a relatively thick bat of non-woven fibrous padding material, such, for example, as cotton linter's disposed and secured in position therebetween. The two layers of fabric are preferably stitched together along spaced substantially parallel lines in order to secure the padding material i in position therebetween and at the same time create a surface structure of substantially tufted effect for ornamental purposes. a The present invention inits principal embodiment contemplates the provision of apparatus 0 for feeding a loosely felted layer of padding material between the two fabric layers and of automatic means for stitching the two fabric-layers together with the padding material disposed therebetween, thestitching being performed along substantially parallel lines. The invention further contemplates means cooperating with the stitching means for pressing the two fabric layers closely adjacent each other just prior to the stitching operation in order to create. the desired tufted or pleated effect. a

An object of the present invention consists in the provision of measuring feed mechanism for feeding the fabric finish material, which measur ing feed mechanism is operated synchronously with the mechanism for feeding the upholstery material through the stitching mechanism.

A further importantfeature of the present invention resides in the provision of mechanism a which greatly facilitates the continuous operation of the apparatus as a Whole in order to effect a great saving in the material used and a 'consequent saving in the cost of manufacture.

In furtherance ofthis last mentioned object, the present invention'contemplates the provision of automatically operated means driven synchronously with respect to the remaining apparatus for feeding a loosely, felted layer of non-woven padding material longitudinally through the apparatus as a whole. Means are further provided, in the event of breakdown of one of the auxiliary 1936, a Serial No. 67,862

Still another particularly important object of I the present invention consists in the provision of means associated with each of the stitching units, which means automatically. serve to actuate mechanism for cutting off and detouring the padding material in the event that one of the threads feeding to thestitching machine breaks. This construction provides one in which the feed of the fabric material, as well as feed of the padding;

is automatically stopped in the event that there is a breakdown of any one of the stitching units. Still further the present invention contemplates the provision of fabric finish layers of material in which the lateral side edges thereof are cutto substantially the final desired form before the fabric finish'material is assembled with respect to the remainder of the upholstery panel. Inasmuch as only the lateral side edges are cut to form prior to the assembly of the panel, it will beI-appreciated that the fabric finish material is retained j in a relatively long strip and may be handled in substantially the same manner as a continuous strip of material on which no cutting operations have been performed.

Many other and further objects, advantages 1 and features of the present invention will become. apparent from the following specification when considered in connection with the accompanying drawings forming a part thereof.

In the drawings:- I

Figure 1 is a fragmentary, perspective view with parts in section illustrating a seat construction upholstered with the improved upholstery panel manufactured by the machine and'in ac-.

cordance with the method of the present invention.

Figure 2 is a sectional view, taken substantially on the line 2- -2 of Figure 1, illustrating in detail the tufted upholstery finishpanel manufactured in accordance with the method and the machine of the present invention.

" Figure 3 is a perspective view, showing the completely assembled upholstery forming apparatus with thevarious units thereof arranged in operative relation with respect to each other.

Figure 4 represents, in plan, the strip of fabric finish material which is fed into the machine for upholof fabric material are fed on either side of the sheet of felted non-woven fibrous padding material and the three members stitched together in unit relation.

Figure 7 is a fragmentary, perspective view, partly in section, taken on the line 1-1 of Figure 6, illustrating one of the trackways for mounting the carriages supporting therolls of backing fabric. I

Figure 8 is a vertical, longitudinal, sectional view of the unit of the machine shown in Figure 6, illustrating in detail the various feeding mechanisms therefor and the relative positions of the parts thereof. v

Figure 9 is an enlarged, fragmentary, -sec-. tional 1 View, illustrating in detail the cut-off mechanism-which serves to interrupt the feed of the padding material in the event of breakdown of any of the unitsof the stitching .mechanism.

Figure .10 isa fragmentary, sectional View, similar ,to Figure 9, showing the cut-cif mechanism after it has-completed a severance ofthe felted bat. I

Figure ll is .an enlarged, fragmentary, pera spective view of'oneof the stitching units and also showing the individual tuftforming and feed mechanism associated therewith.

Figure 12 is a sectional view, takensubstantially in the line. i2-i2 of Figure 11', illustrating the-:mounting of one of thesprockets .of the tuft trating the pleat forming and fabric feed 'mechaa forming and. feed mechanism.

Figure .13 is .a fragmentary plan view, illusnismshowing the manner-in which the pleat forming chains converse toward each other to produce the required pleat fullness.

Figure '14 is-an enlarged, sectional View, taken substantially on the .line M-M of- Figure 13, illustrating the manner in which the finish fabric is fed-into engagement with the'padding material. Figure 15 :is .an enlarged, fragmentary, .sectional view, taken substantially on theline 15-45 of Figure 13, illustrating the mannerin which the-pleats :or tufts .are formed.

Figure .16 :is a fragmentary, perspective view, illustrating a modified form or tuftv forming mechanism which operates directly upon the padding material prior to the applicationof the finishimaterial.

Figure 1'7 is an enlarged, fragmentary, sectional View, taken substantially on the line I l- 41 of Figure 16, showing in detail the inter-engaging rollers which serve to form :tufts in the padded material.

Figure 17a is a sectional view, illustratingmthe form of the padding mat-erial-after-it has been subjectedto the action of' the mechanism-shown in'l 'igures 16 and 17. I

Figure 18 is a fragmentary, perspective View of a st-i'il further modified form Oftuft forming mechanism :in which the padding .material is partially severed :a-long substantially longitudinal lines.

Figure 19 is an enlarged, sectional View, taken substantially onthe line 19-49 of Figure 18,

' one of the stitching units.

showing in detail one of the cutter wheels and" 1 its engagement with the padding. 1

padding mechanism in the event of breakdown of 1 Figure 21 isa side elevational View of the upholstery forming unit of the machine illustrating the drive mechanism therefor and the manner in "which the-respective parts thereof are correlated.

Figure 20 is .a circuit diagram, illustrating the automatic means for controlling the feed of the "With moreparticular reference to the drawings, it will be appreciated that the specific embodimentof theinvention illustratedtherein and described below, relates to the formation of upholstery trim panels such as are conventionally used in the formation of vehicle seat-cushions and seat backs substantially ofkthe type i1lustrated in Figure l. Cushion constructionsof this generic typegenerally comprise a rectangular framework it serving -tosupport a plurality-of:

coil springs H. The upper ends of 'the coil springs. ,are prefera-bly covered with a .:layer 'of burlap or other fabrichacking materialql2 to which is applied a'suitablelayer'of padding 13. The upholstery trim panels with which the pres ent invention is primarily concerned are applied directiy over .the layer of padding l3. panels, ait will be seen, comprise a backing iayer 15 of suitable woven fabric material; and *a finish layer It of woven .mater-ial adapted to provide an attractive ,finish for the seat constructionand an intermediatelayer of non-woven fibrous material such, forexample, as cottonlinters-secured-between the fabric layers 15 and iii. The,

layers of fabric material i5'and ifiare'preferabiy secured together along substantially parallel spaced lines, by stitching cl 8 to form an attrac .tive tufted orwpleated exterior surface, Wh'iGh; lines of: stitching also serve the purpose of ree' taining the non woven felted-cottoniinters in position between the two fabric layers. I

- The apparatus of .the present invention :is ,1

primarily conceined'with the provision of means for automatically and continuously forming upholstery :panels such as are shownin -the =isec .tional view in Figure 2.

In Figure 3 These is illustrated the complete -.:asa semblyuof one embodiment of" the mechanism provided by. thepreseht invention for .thE COH- tinuous formatiomof upholstery trim panels such f as havebeen described .above.

The layout unit which is seen .in the. lower left-hand portion of Figure 3 is shown as placed in line with the remainder of the apparatus, but

the position of this unit is not particularly. important inasmuch-as it does not, in fact,-physically cooperate with any of the remaining units of the machine. the purpose of preparing continuous stripsof fabric finish material for utilization inpthe up holstery forming mechanism of the apparatus described in detail below. This layout unit com-v prises a Work table 2fi of substantial longitudinal This layout unit is utilized for length which has-a fiat top .21 *of a width slightly wider than the fabric finish trim material to he prepared. Securely mounted in spaced re "on longitudinally extending trackways 22 which serve to, provide meansfor movably'mountingra layout carriage 23, the construction and opera.-

tion of which is described in detail in applicantis will be fed therefrom in a substantially uniform,

ri'age 23, provides means for mounting a pair of rolls 24 of fabric finish material. Means are provided upon the carriage for automatically moving the carriage longitudinally with respect to the work table on which it is mounted. The carriage includes thereon measuring feed mechanism to unroll cloth from the rolls 24 and lay it out upon the table in flat, uniform, superimposed layers 25. A suitable weight 26 may be utilized for the purpose of maintaining these strips of fabric material in predetermined superimposed relation and after a suitable number of layers have been stacked one upon another, the entire stack is trimmed by means of an electrically operated cutter 21 to form the lateral edges of the finish material to the desired configuration. As will be clearly seen by reference to Figures 4 and 5, the lateral edges of the strips of cloth are trimmed to provide a configuration substantially as will be desired in the lateral edges of the finished upholstery panels while the panels as a whole are not trimmed at their top and bottom edges; consequently, it will be seen that after the trimming operation has been performed, the fabric finish material will still retain its continuity as a single integral strip of cloth which maybe rewound by the traveling carriage 23 in substantially the same manner in which it was unwound and laid upon the table. After the fabric finish material has been laid out and has had its lateral edges trimmed, the finish material is rewound into a roll 28 of substantial diameter and supported in bearings upon the upholstery forming mechanism hereinafter described in detail.

The mechanism for automatically preparing and forming a continuous bat of loosely felted, non-woven cotton linters for utilization as padding in the upholstery panels is shown in Figure 3. This mechanism preferablycomprises a pair of Garnett machines 30 and 3| which are preferably disposed side by side at the lateral side of the apparatus as a whole. These machines are substantially conventional in construction and cotton linters or other suitable similar non-woven fibrous material may be fed thereinto and will be combed and beaten until the fibers are distributed substantially at random and fed from these machines upon a pair of endless conveyor belts 32 ;and 33, respectively, which feed this bat to a second pair of reciprocably mounted conveyors 34 and 35, which extend over the main feed mechanism of the apparatus hereinafter described in detail.

As is conventional in structures of this kind, a plurality of trackways 36 extend transversely of the apparatus as a whole and serve to provide means for movably mounting the forward end of the endless conveyors 34 and 35. Suitable means, not shown, such as is conventional in the art, may be provided for automatically reciprocating the forward ends of the conveyors. 34 and backand forth along the trackways 35 in order that the loose non-woven fibrous material matted layer upon a longitudinally extending conveyor belt 31 mounted in a suitable longitudinally extending framework 38. It. will be appreciated that the construction described above serves to provide a felted bat 33 of padding material leaving the pad forming unit on the belt 31, and it will be clear that the thickness of this padding material may be accurately regulated by regulating the rate of operation of the pad forming machines 30 and 3| with respect to therate of travel of the conveyor belt 31.

It will be seen by reference to Figures 3, 5, 8, 9 and 10 that the conveyor belt 31 serves to move this bat or uniform layer of fibrous padding material up into and feed the same into the rear end of the upholstery forming mechanism here inafter described in detail.

As will be seen clearly by reference to Figures 9 and 10, the forward end of the conveyor belt 31 passes over a suitable roller 40 which cooperates throughout its body portion with a fixed plane surface work table extending throughout substantially the entire width thereof. A pair of housings 5! are provided underneath this work table adapted to receive rolls 52 of backing cloth. These rolls 52 are preferably journaled for rotation in carriages 53 provided with suitable fianged wheels 54 adapted to run in trackways 55 which may be formed substantially in the floor level such as is shown in detail in the fragmentary perspective view, Figure 'I.

It will be appreciated that the above described construction permits the installation of two rolls of backing cloth in the upholstery'forming machine, only one of which isfed into the machine at a time. It will be apparent that when one roll isnearly exhausted, the leadingend of the cloth material on the other roll may be connected thereto and fed directly into the machine, thus preventing the necessity of stopping the mechanism during the connection of a new roll of cloth. The structure provided makes the substitution of a new roll for an exhausted one a relatively simple operation which may be accomplished without in any way disturbing the operation of the machine. 1

Figure 8, the cloth is unwound from the roll 52 and passes upwardly around an idle roller 51, the L which is described in detail below.

It will be apparent that the matted felted layer. of fibrous material 39, as it is fed into this up-' holstery forming unit, will be fed in on top of this layer ofbacking material and will. be carried along the work table 58 thereby into the stitching mechanism. v

A shield 58, arranged substantially parallel with the work table 50, and spaced thereabove, serves to maintain the bat 39 in engagement with the backing material 52 as it passes along the work table 50 and it will be noted that this shield 58 is flared at its rearward end 59 to facilitate the entry of the padding material between the work table and the shield.

The roll of fabric finish material 28, which has its lateral edges cut to form as described above, is mounted upon a pair of supports extending 50:, As may clearly be seen from the sectional View,

provided at their upper ends with suitable bearings 66 which serve to support a shaft running axially through the roll 23 to permit free rotation thereof with respect to the frames in which it is mounted. This shaft is also adapted to seat on the reel supporting members in the lay-out mechanism described in the prior co -pending application referred to above. An endless belt 67 is mounted upon a plurality of transversely extending freely rotatable rollers 68, which are positioned in such a manner that the belt 6'! will resiliently engage a substantial portion of the peripheral surface of the roll of fabric finish material 28. In order to effect engagement of the belt 6! with the roll 28 at all times, irrespective of the diameter of the roll, a pair of arms 1!] are pivotally mounted on each of the side frames l5 and 46 and serve to provide in their upper ends means for rotatably mounting an idle roll H.

These arms '50 have portions 12 which extend past,

the'pivct point of the arms and each has secured thereto one end of a tension coil spring 73 which Y serves to urge this roller H into engagement with the roll of fabric finish material 28 at all times and serves to aid in maintaining the belt 6'5 properly resiliently tensioned irrespective of the diameter of the roll of cloth 28. In addition, the

belt 6'! may be tensioned by a second roll 75, journaled for rotation in the ends of a pair of arms 76 which are pivotally mounted on the frames 45 and it at a point 'l'l intermediate the ends of the arms. The opposite ends of these arms provide means for attaching the opposite end of the coil. spring 13 described above.

From the foregoing, it will be clear thatthe rolls 15 and l I, together with their pivotal mounting arms, and the tension coil springs 13, serve to maintain the belt 61 properly tensioned at all times irrespective of the diameter of the roll of cloth which it engages.

Cloth may be fed from the roll 28 down along the conveyor belt 61 and on to a frame compris .ing a plurality of longitudinally extending, con-v verging, upwardly presenting channel .members' 86. These channel members may be maintained in predetermined relative position by means of suitable transversely extending frame members 8|, one of which is shown in Figure 11. The framework as a whole slopes generally downward ly and forwardly in order that cloth carried on the surface thereof will be brought gradually down and delivered into engagement with the felted padding material 39 which, as has been explained above, lies on top of and is carried along by the backing sheet 52 on top of the work table 50.

When the roll of fabric finish material 28 is approaching exhaustion, a second roll of this material is swung adjacent thereto by means of a suitable overhead crane and the terminal end of the fabric finish strip 28 is secured to the leading end of the new roll and the new roll is then mounted in position, thus providing an uninterrupted and constant supply of fabric finish material to themachine. From the foregoing it will be appreciated that the machine as a whole may be operated continuously and without interruption for as long a period as may be desired.

A framework, generally designated as 90, is pivotaliy mounted upon a shaft 9! extending transversely of the conveyor system as a whole and is adapted to be swung down into engagement with the channel framework 80. The framework has a shaft 92 rotatably mounted therein at the end thereof'opposite to the end at which it is pivoted, and it will be seen by reference to Figure 13 that a plurality-of sprocket wheels are permanently secured to each of the shafts 9| and 92. Sprocket chains extend between each of the sprocket wheels 93 and 94, and it will be,

appreciated by reference to Figure 13 that the sprocket wheels 93 on the shaft 9| are considerably more closely spaced than the sprocket wheels 94 on the shaft 92. Consequently, as the chains 95 approach the forward end of the frame, they become closer and closer together. It will be seen by referenceto Figure 11 that one of these sprocket chains is positioned to cooperate with each of the upwardly presenting channel memhers 80 in the framework over which they lie. As 3 is conventional in structures of this kind, a takeup or idler roller 96 may be journaled in oneend of a suitable pivoted bell crank 97, the opposite end of which is controlled by a spring 98 to main-- tain the sprocket chains tight at all times] The blocks between adjacent links in the sprocket chains 95 are provided with outwardly projecting, sharply pointed pins I90, which, it willbe seen, serve to extend into the channel member with which the chain cooperates Each of the sprocket chain assemblies may be covered by a suitable sheet metal housing lfll, as may be desired, and, as is clear by reference to Figure 11, this housing may serve to provide means for pivotally mounting the bell crank member .ll'of the take-up mechanism.

The shaft 3! is rotated by means hereinafter I described in detail to simultaneously .drive all of the sprocket wheels 93 thereon and consequently drive theisprocket chain 95 carried thereby. It will be appreciated that as the finish fabric material 25 is fed in. on top of the framework 80, the projecting pin lllll'will project through the material and move this material along the framework. at a rate corresponding exactly with the rate of speed at which the sprockets'93 are driven. Due to the fact thatthe channel members 83 slope gradually downward, it will be apparent that this material will be gradually brought into close proximity with the upper surface of "the padding layer 39, which,

as has been described above, is disposed on top of the fabric backing sheet of material on the work table 50. Due to the convergence. laterally toward each other of the channel members 80 and their cooperating sprocket chains, it will be seen that the fabric finish material is brought laterally inward in order to provide the excess thereof required for the desired pleat fullness.

The three superimposed layers, namely, the backing sheet, padding layer, and the'fabric finish material, pass from the upholstery form-,

ing unit to the stitching unit, also shown in the sectional view,. Figure 8. This stitching unit comprises a pair of laterally spaced frames Hi5, located on either side of the work, having mounted therein a roller I06 which serves tosupport the rear end of a conveyor belt fill, the upper surface of which belt, it will be seen, lies sub-' stantially in the plane of the work table st of I the upholstery forming machine. A feed roll Hi8 is driven by means hereinafter described, upon a transverse axis and is preferably urged by means of springs I09 into engagement with the upper surfaceof the conveyor belt H31. It will be seen that these cooperating rollers I66 and H38 serve to feed the material through the sewmg mechanism and draw the material alsothrough the upholsteryforming unit'described It is,v however, inevitable that the stitching above. I I v A plurality of sewing machines of substantially conventional form are arranged in spaced relationtransversely across the line of travel of the work. I The sewing machines making: up the stitchingunit preferably comprise a plurality of vertically disposed needles-III), operated by rods III, actuated by a transversely extending cam shaft H2 common toall of the sewing machines. I Each of the needles II!) may be supplied with a suitable source o f't-hread H3. Beneath the work'table, the machines are provided with conventional 'loopers H4 for. cooperating with the needles III) and this lower assembly may also be supplied by a separate source of thread II5. l l

The. sewing machines .are. spaced laterally from one another in accordance with the spacing of the sprocket wheels 93 on the shaft BI and each sewing machine is provided with a forwardly extending foot I20. which is preferably resiliently mounted for vertical movement and urged down-.

wardly towardthe surface of the work. table'by means of a compressionco-il spring I25. This forwardly extending foot is preferably-bifurcated at its forward endto provide'an upturned fork I22, whichextends on either side of the sprocket chain with which it cooperates; I't-will conse: quently be apparent that'material fed forwardly by the sprocket chains will be forced in underneath the foot, and due to the curvature of the foot will'be forced downwardly and separated from, the pins in the chain an'd'closely into 'engagement with the upper surfaceof the work table over which the material is travelling. I It will be apparent that this foot structure servesto compress the loose fibrous material between the fabric finish layer and the backing sheet, and due to the fact that the fabric finishlayer has been gathered in by the convergingsproclret chains 95, sufficient finish material will be'available to provide the-necessary pleated or tufted effect, and consequently the fabric finish layer may be stitched by each of; the sewing machines closely into engagement with the backing sheets along longitudinallyextending parallel lines. 1-

From the foregoing, it will be apparent'that a continuous composite upholsteredstrip will be fed outwardly along the conveyor belt Ill! from the stitching unit. This, composite strip will comprise a backing layer and a fabric finish layer with the padding or upholstery therebetween and these members will all be secured together along substantiallylongitudinal lines providing I longitudinally extending tufts" or pleats. p 1 I Referring again to Figure 3, it will be clear that, as this material leaves the stitching unit,

it: may be fed outwardly onto a work table I20,.

where the strip maybe severed Ito provide separate individual upholstery panels IZI. These adjacent-panels may be out from one another by means of a suitable electrically-operated cut--:

ting mechanism I22, similar in construction vand operation to the cutter 2'1 referred to above.

. As has been explained above,.'the two rolls of backing material located in the housing 5| underneath the work table preciated from the above description that the Garnettingmachines 3H1a'nd 3| serve to provide a continuous web of loosely felted-cotton linters providing a padding =web between the backing and finish layers of the upholsterypanelsw 50 provides structure whereby a continuous web of'backing material I may be fed into the machinefand'it'will be ap-- unit must be stopped from time to time in order to repair broken threads or broken needles and adjust the mechanism thereof. Consequently, the

present invention contemplates the provision of automatic means for immediately arresting the movement of the padding material through the upholstery forming unit, cutting off the back of padding material being fed thereinto, and. de-

touring this cut-off portion away from the up holstery' formingunit inorder'that the Garnett machine and padforming mechanism will not have to be stopped during the time when it is necessary to stop the operation of the stitching unit Thisis accomplished by means'of a hydraulic cylinder l3l actuated by means hereinafter described in detail 1 of the roller lil and these sectors have extending therebetween a tablesection I31 which-is normally, during operation of the machine, adapted to lie in the same plane as the transversely eX-- I35. The transversely extending tending. table operating rod sectors lee. ment of thepiston of the hydraulic cylinderycon- I32 is directly connected to the struction I3I will serve to cause simultaneous.

pivotalmovement of the sectors ,l36 about their pivot point and consequently will serve to'mcve the table structure-I3"! a'rcuately downwardly with respect to the plane of the work tables I35 and Eli.

It will be seen that vertical move' sectors I36 are pivotaly mounted upon the axis The sectors l36 are also interconnected by means of an arcuately curved blade mounting member Hill, in which is'mounted a transversely'extending cutter blade I lI, which serves to cooperate with the rear edge of the table I to provide a shear for cutting off the forwardly moving strip of padding. material 39, when the sectors I36 are moved arcuately about their pivots by the hydraulic cylinder construction I3 I. I44 are mounted for pivotal movement about the axis of rotation of the'roller lI. These arms are ing unit and-have extending therebetween a brake shoe I45, which serves to cooperate with the upper surface of the table 135 to arrest movement of the fibrous padding material when the'operation which may be anchored to the framework.

The transversely extending knife supporting bar I49 has, on the upper surface thereof, a pair of brackets Ml which serve to support rollers 18 adapted to vcontact the arcuately' curved underside of the brake, arm Hi l. The'under-sides of these brake arms M' t'are preferably curved to provide a cam surface M801" such curvature that when the sectors I36 are swung downwardly to cut off the padding material, thebrake arm will be permitted to move downwardly, thus clamping sume substantially the position shown in Figure 10 ofthe drawings.

= It will be seen by reference to this figure that A pair of brake arms disposed on opposite sides of the'upholstery' form- 7 cf the stitching mechanism is interrupted. This brake assembly is at all times urged toward the.

table I35-by means of a tension coil spring its,

the web of padding material has been cut off and theforward end thereof is directed -downwardly underneath the table I35 and it will be seen that, as further-forward movement of this padding material takes place, it will be fed into contact with the arcuately curved shield I58; which will serve to direct this bat or strip of padding material downwardly onto a conveyor belt i52' disposed underneath the conveyor belt 31 in the frame of the pad forming mechanism. It will be apparent that during the time the sewing machine is stopped, the Garnett machines 3!! and SI may remain in operation and the padding material generated thereby will be fed onto the conveyor belt I52 from whence it may be moved and r-eturnedto the Garnett machine. The upper edge of the shield i5t' is bent downwardly and. sharpened to form a transversely extending knife edge I55 which serves to cooperate with the forward edge of the-table portion i3? to'agai'n cut off the web of padding material when .the sector members ltd are returned to their normal position. It will be apparent that when the sector members I236 are urged upwardly to the position shown in Fig. 9, the web of padding material will be cut off by theknife edge I and this cut off end portion will be brought directly into engagement with the butt end of the strip of padding material which has been retained in the upholstery form ing mechanism by the brake shoe ME.

It will further be apparent that upward movement of the sectors I36 will cause the brake shoe M5 to lie-raised from the padding material in the upholstery forming machine and consequently permit the resumption of forward movement thereof with the forward end of the padding material being fed in in closely abutting relation with the rear end of the padding material which has been retained in the upholstery forming machine during the interruption of the operation thereof.

It is highly desirable that the conveyor 36,,

which feeds the completed strip from the. ma-

chine, the sprocket chains 95 which feed the fin-, i'sh material into the apparatus, the conveyor .57 I

which feeds the finish material to the sprocket chains, and the conveyor 3'! which feeds the padding material into thev upholstery forming ma-v chine, be all run at a speed which will produce a substantially uniform rate of travel of all of the relative members longitudinallywith respect to the apparatus as a whole.

. As has been explained above, the rate of operation of the Garnett machine should be carefully proportioned with respect to the rate, of travel of the conveyor 31in order to effect the creation of a layer of padding material of the desired weight and thickness, and it is consequently de sirable thatthe Gamett machines be operated-in synchronism with the remainder of the apparatus.

to preform the padding material prior to its insertion between the fabric finish sheet and the backing sheet in order that the tufts therein will be substantially preformed prior to its insertion between the fabric finish layer and the backing sheet. In Figures 16 and 17 of the'drawings; I

have illustrated one form of mechanism which may be utilized for accomplishing this result. It will be appreciated that the mechanism hereinafter. described may be inserted into the above described system at any suitable point past which the formed padding material passes prior to its insertion between the backing sheet and the fab In the specific embodiment of I ric finish layer. the invention shown in the drawings, the apholstery forming unit is driven In certain instances, it has been found desirable shaft I is provided witha plurality. of: spaced forming wheels III. These wheels are spaced apart on the shaft in accordance with the spacing of the lines of the stitching in the resultant panel structure. The bat I12 is fed in between these;

Wheelsand cooperating; grooved wheels I13,

mounted for rotation on a shaft I'M beneath the I level of the table. The grooved Wheels 113 may be provided with upstanding circumferentially extending cutting edges I in the base of the groove in order to cut ortear the fibrous material sectional view'in Figure 17a.

A still further modified form. of construction is illustrated in Figuresv l8 and 19. vIt will be seen that this apparatus is preferably mounted over the work table 50 after the padding material has been fed in on top of the backing web. "A trans- I versely'extending' shaft I8!) is provided with a plurality of spaced, circular cutters I8I which serve to cut the strip of padding material partially" 'paratus is shown as mounted just forwardly of the table section I35. A transversely extending through along longitudinal lines spaced apart in accordance with-the spacing of the stitching mechanism .bywhich the fabric finish layer is secured to the backingweb. A transversely extending shaft I82 may be provided adjacentthe shaft I853 .andmay carrythereon a plurality of rotary sharpening elements I 83 which may be urged into engagement with the knives I85 when it is desirable to sharpen the same. extending shafts I85 and I86 may be disposedin front of and behind the shaft I89. carrying the cutters and these shafts may carry a plurality of pulleys I87 and I88, respectively, which serve to mount feed belts I89, operated in synchronism with the rate of travel of these backing sheets and padding material through the mechanism. It has been found that'partially severing the 'padding' rnaterial alonglongitudinal lines serves to greatly facilitate. the formationof the'tufted or pleated structure.- I y I The specific manner 'in which 'the upholstery forming unit is synchronously driven and controlled is best understood by reference to the circuit diagram of Fig. 20 and the diagrammatic side elevational view of Figure 21.

electric motor or other source of power 200, which is preferably mounted in the frame of the stitch- 'ing mechanism. This motor has secured thereto The entire up by means of an 'Iransversely .a gear Z-IH, which by means of a sprocket chain 28ft, serves to drive a gear 203 secured to a transversely extending shaft 2IM journaled for rotation in suitable bearings in the-side frame" I05 of the stitching unit. The shaft '204 has'at each of its ends, pulleys 205 c 60 i secured thereto; which serve to p drive belts 205 which run over pulleysZt'Iv secured to the oppositeends of the cam shaft I'i2which serves to operate the stitching needles.

As is conventional in constructions of this kind, the belt may be maintained taut by means of a suitable idle pulley or roller 2B8 journaled in the end of a pivotally mounted arm 299 and resiliently urged intoengagement with the beltfiflfi by means of a suitable spring ZIG. It; will be appreciated that the relative diameters of the pulleys 205 and 26? may be varied in order that the speed at which the cam shaft l lzdriving the stitching mechanism is rotated may be :controlled within desired limits. a

2,188,995 A bevel gear 2 I5 is secured to the cam shaft I I2 a suitable transversely extending shaft for.-

operating the looper mechanisms which cooperate with the various needles.

In its central portion the shaft 2!! is provided with a sprocket wheeLwhich serves, by means of 7 suitable sprocket chain 220,'to drive a sprocket wheel on the upper end of a second vertically extending shaft'22l. The lower end of this shaft 22l has secured thereto a worm 222 which meshes with a worm wheel 223. The worm wheel 223 is secured to the shaft of the roller 106 which serves to operate the conveyor I01. Also secured to this shaft is a large gear 225 which meshes with a second large gear of equal size 226 carried by the roller I08. f

From the above described structure, it will be apparent that the electric motor 200. serves'to drive the needle operating mechanism by means of a belt 206. It will furtherbe appreciated that the drive of the conveyor operating roller I06 and the feed roller I08, which together serve to draw the upholstery material through the upholstery forming unit, are positively driven in synchronism with the sewing machines and the various gearing elements are so proportioned that the speed of this mechanism will be synchronous with the rate of speed of the sewing machine itself. The shaft of the roller I06 also has'secured thereto a sprocket wheel 230, which, by meansof a-sprocket chain 23l, serves to drive the shaft 94 which actuates the measuring feed mechanism for the finish material. Consequently, it will be apparent that this mechanism also is operated synchronously with the feed rollers Illli and H18.

Power from this same source may be utilized to I drive the measuring feed belt 61 which delivers 243 are connected is substantially conventional the fabric finish material to the pleat forming mechanism and this drive may be accomplished by means of a suitable sprocket chain 235 which drives a sprocket 236 secured to the shaft of one of the rollers 68. I v I The automatic means serving to actuate the hydraulic cylinder I3! is best illustrated in the circuit diagram of Figure 20. In the construction shown in this figure, it will be seen that current is fed in from a suitable source by means of wires 240 and passes through a suitable transformer 24! serving to illuminate. a plurality of lamps 242. A photo-electric cell 243 is associatcd with each of the lamps 242. It has been found preferable to provide'a lamp and the photo-electric cell for each of thethreads passing into the sewing mechanism and means are provided for screening the rays of the lamp from the photo-electric cell in the event't'hat one of the threads breaks. 4 I l The circuit in which the photo-electric cells in construction, and it will be seen that the current therefrom serves to actuate a relay 244 which, when a starting switch 245 is closed, serves to actuate the magnetically operated master switch 246 by means of a solenoid 241. 'This master switch not only controls the circiut to the motor 200 but also serves to energize a solenoid 250 which actuates a four-way valve 248 serving to control the admission of fluid pressure to the hydraulic'cylinderlfl. I I

I From the foregoing, it will beapparent that of them are screened from their respective photo-electric cells, current will be supplied both to the motor 200 and to the solenoid 2451, thus retaining "the valves 248 in a position to supply fluid pressure to the hydraulic cylinder E31, In this position, it will be appreciated that the sectors 135, together with their table Nil, are retained in substantially the position as shown in Figure 9, and the continuous web of felted fibrous material will be drawn through the upholstery forming machine. In the event that one of the threads to one of the stitching units should break,

it will be apparent that immediately light will be ing the switch 246, which will not only cut off the motor 2%, drivingthe upholstery forming mechanism, butwill also'serve to relievefiuid pressure from the hydraulic cylinder lSI and consequently compel the sector members 136110 as long as the lights 242 are energized and none move to substantially the position shown in Figure 10, thus detouring the bat fed by the pad forming unit. When the sewing machine has been repaired, it will vbe appreciated that the respective units thereof will be restored to substantially their original position and operation will be continued as has been described above.

It will be appreciated that the neric inventive conceptpresented in this application is sus-' ceptible of many and various modifications falling within the scope of the invention defined'in the .subjoined claims.

We claim as our invention:

1. In an upholstery forming machine, means for generating a substantially continuous web of paddingmaterial, means for feeding said padding material into an upholstery forming unit, cutoff mechanism in said upholstery forming unit for shearing off said strip of padding material when operation of said upholstery forming unit is interrupted, and means for detouring said web of padding material during the time said up-' holstery forming unit is not operating 2. An upholstery forming machine comprising -mechanism for forming and continuously feeding a strip of fibrous, non-woven, padding material through said machine, releasable clamping mechanism serving to lock said padding material against feed movement through said machine, stitching mechanism, means for feeding a layer of fabric finish material on top of said clamping mechanism when said stitching machine is stopped.

3. An upholstery forming machine comprising mechanism for forming and continuously feeding a' strip of fibrous, non-woven, padding material through said v machine, releasable clamping mechanism serving to lock said padding material against feed movement through said machine,

stitching mechanism, means for feeding a layer of fabric finish material on top of said padding material, means for feeding a backing sheet on the under side of said padding material prior to feeding the same to said stitching mechanism,

means for feedingv electric current to said stitch-' ing mechanism to operate the same, and means responsive to an interruption in said spply of; current for actuating said clamping'mechanism.

CLARENCE W. AVERY. ALFRED HABERSTUMPL 

